Structural building system

ABSTRACT

A low-cost, high quality structural building system of interlocking hollow components which fulfill the structural and decorative requirements of both the interior and exterior surfaces of walls, or both surfaces of interior partitions, floors, ceilings, and rooves if desired, with windows and doors being interlockable therein, the components collectively enclosing the skeletal structural supports which complement these components, and to which these components are anchored.

United States Patent Charles Kay Wyoming, Mich.

May 20, 1969 Sept. 7, 1971 J. Raymond Christy Enterprises, Inc. GrandRapids, Mich.

Inventor Appl. No. Filed Patented Assignee STRUCTURAL BUILDING SYSTEM 4Claims, 11 Drawing Figs.

US. Cl 52/281, 52/284, 52/404, 52/562, 52/593 Int. Cl E041) 2/16, E0401/10 Field of Search 52/562,

[56] References Cited UNITED STATES PATENTS 2,362,162 11/1944 Sheldon52/271 X 2,401,587 6/1946 Smith 52/474 2,480,612 8/1949 Sherman 52/562 X3,001,613 9/1961 McBerty 52/405 X 3,286,428 11/1966 Kay 52/562 X3,350,824 11/1967 Wiebusch.. 52/496 X 3,452,498 7/1969 Kinsey 52/284 XPrimary Examiner-Price C. Faw, Jr. AttorneyPrice, Heneveld, Huizenga &Cooper ABSTRACT: A low-cost, high quality structural building system ofinterlocking hollow components which fulfill the structural anddecorative requirements of both the interior and exterior surfaces ofwalls, or both surfaces of interior partitions, floors, ceilings, androoves if desired, with windows and doors being interlockable therein,the components collectively enclosing the skeletal structural supportswhich complement these components, and to which these components areanchored.

PATENTED SEP 1 m sum 1 012 INVENTOR 0 CHARLES KAY a051,

BY W

ATTORNEYS I PATENTED SEP 1 l9?! SHEET 2 [IF 2 INVENTOR H CHARLES KAY Q WATTORNEYS STRUCTURAL BUILDING SYSTEM BACKGROUND or THE INVENTION Thisinvention relates to building construction, and more particularly to abuilding system employing similar cooperative interlocking hollowcomponents with an interlocked skeletal framework.

In recent years, the tremendous increase in cost of and shortage ofsupply of both building materials and skilled labor have contributedsignificantly to the housing shortage and high-cost problems. As is wellknown, conventional construction of houses and similar buildings employsa tremendous quantity of lumber, including closely spaced and anchoredstuds for wall structural support, closely spaced beams and rafters foroverhead structural support, and several layers of internal and externalsupport and decorative materials, usually plywood sheeting. Upon theseare applied decorative layers of plastic, paper, paint, wood paneling,etc. To construct a structure employing these materials and techniquesrequires exceptional skill, a great amount of time, and a verysubstantial amount of money, as is well known.

In my US. Pat. No. 3,286,428 is set forth a wall constructed of novelblock elements. This present invention constitutes an improvement ofthat structure in this prior patent employing a unique combination ofelements of this type interlocked with skeletal framework elementsencompassed within the ele ments.

SUMMARY OF THE INVENTION It is an object of this invention to provide abuilding construction with double face structural panels forexterior-interior structural walls, interior partition walls, ceilings,floors, and roofs. These are rapidly formed and securely anchored usingan interlocked skeletal framework, the framework becoming completelyenclosed within the panel. The electrical wiring, plumbing, thermalinsulation, and heating and cooling ducts are enclosed within the panel.The window and door casings are interlocked as integral portions of thepanel in desired number and locations.

An entire building can be erected rapidly, with a minimum of skill andat a fraction of the cost of conventional construction.

The building elements are specially made to be anchored to the frameworkcomponents and encompass the components.

These and other objects, features and advantages will become apparentupon studying the following specification in conjunction with thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary perspectiveview of the interior of a portion of a building constructed according tothis invention;

FIG. 2 is a fragmentary enlarged perspective view of a comer conjunctionof two partitions of a structure made according to this invention;

FIG. 3 is a fragmentary enlarged perspective view of a modified cornerof two joining partitions of a structure made according to thisinvention;

FIG. 4 is a fragmentary plan view of the construction in FIG.

FIG. 5 is a fragmentary perspective view showing the lower portion ofoneof the partitions in FIG. 3;

FIG. 6 is a fragmentary perspective view of the upper portion of apartition made in accordance with this invention;

FIG. 7 is an enlarged fragmentary view showing a partition according tothis invention into which a window is interlocked;

FIG. 8 is a fragmentary elevational view of a building wall and roofconstruction made in accordance with the teachings of this invention;

FIG. 9 is a fragmentary enlarged view of a portion of the structure inFIG. 8;

FIG. 10 is a fragmentary perspective view showing a floor and wallconstruction made in accordance with the teachings of this invention;and 7 FIG. 11 is a fragmentary perspective view of a portion of amodified element of the system.

DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIG. 1, buildingconstruction 10 includes an end wall partition 12, an interior wallpartition 14, a floor partition 16, and a combined ceiling-roofpartition 18. Partitions l2, l4, and 16 are made in accordance with theteachings of this invention. Each of these partitions is composed of aplurality of interfitting double wall elements of elongatedconfiguration, and interlocked structural skeletal struts encompassedwithin the elements. The elongated elements may be vertically arrangedas in FIG. 2, or horizontally arranged as in FIG. 3 or FIG. 2. These arespecially interfitted with the structural framework members, normallytwo by fours which may take the form of a toe plate 22, upstanding studs24 and 26, and cap plates 28 (FIG. 6) sometimes referred to herein asstruts."

Each of elements 20 is composed of a pair of like elongated panels 20aand 20b interconnected by a plurality of spaced transverse metalconnecting plates 21. These are normally in the range of about 0.015 toabout0.060 inch thickness. Elements 20 may be of any desired length,e.g. the full length of the partition, or a fractional portion thereof.These elements are capable of being interfrtted with each other by meansof elongated grooves and tongues on opposite edges of each of the panels20a and 20b, i.e., along their length, and preferably also tongue andgroove connections on ends of the panelsvie, along the heights of thepanels, as that-term is used herein. Normally, panels 20a and 20b aremade of wood, but other materials could conceivably be employed. Plates21 are normal to, extend between, and interconnect panels 20a and 20b,with the ends of plates 21 having transverse flanges generally parallelwith panels 20a and 20b and normal to the remainder of the plate. Theseflanges and adjacent end portions of the plates are embedded in panels20a and 20b to securely interlock them prior to construction of thebuilding. Plates 21 normally have a length a little less than the widthof panels 20a and 20b for full support.

Of plurality of elements 20 interfitted in a partition, those at theedge of the particular partition, i.e. edge elements are of specialconstruction to enable the integrated structure to be formed in aspecial manner. Specifically, these edge elements have differentdimensioned plates interconnecting the panels. These plates 121 have aplate length less than the height of the panels by an amount at leastequal to the width of the skeletal framework struts, normally a nominaltwo by four, to enable these edge elements to each receive and encompassthe width of at least one of these skeletal strut members within itsconfines, whether such skeletal support strut member be a toe plate asat 22, a cap or double cap as at 28, a stud as at 24 and 26, or other.The short plates 121 are offset toward one edge of the panels to whichthey are joined, in aligned relation, enabling the skeletal strut memberto lie alongside them within the confines of the double panel element20a. Assembly thereof is explained hereinafter.

Although the number of a skeletal strut members can be varied, only arelatively small number of these framework members need be used. Thus,to erect a vertical partition as 14 in FIG. 1, using verticallyextending elements 20, it is only necessary to attach a toe plate, e.g.22 to the floor, attach a corresponding aligned cap adjacent theceiling, cut elements 20 to length, inter-engage the tongues and groovesof a plurality of these elements 20 while sliding them over the toeplate and cap, and anchor them to the toe plate and cap with nails. Thespecial edge elements are employed on the ends of the formed partition,with a pair of upstanding studs being received therein. The wall panelshown on the right side of FIG. 2 would thus be formed for example fromright to left, with special edge element 120 being the last one to beattachedto the toe and cap plates. Then stud 24 would be placed betweenthe panels of edge element 120 and tacked thereto as well as to the toeand cap plates. If the wall is long, extra strength may be added byforcing one or more two by fours horizontally between the collectivepanels and between the plates prior to attaching this last stud.

With completion of this partition, if it is desired to extend anotherpartition therefrom, e.g. as at the left side of FIG. 2, this may bedone using either vertically oriented or horizontally oriented elements20. If the horizontally oriented technique is to be employed asillustrated in FIG. 2, stud 26 is attached to the outside of one of thepanels of edge element 120 and a new toe plate 22' is attached to thefloor extending normal studs 24 and 26 and normal to toe plate 22.Hence, the skeletal framework extends in three dimensions from thecommon corner point. Another special edge element 120 is then placedwith its metal plates adjacent its upper edge and its receiving spacedown over toe plate 22 so that its panels straddle the width of the toeplate and its plates are immediately adjacent and above it. Then severalelements are interfitted one atop the other to form the main body of thepartition. Preferably the outer panel 20b of each of these elementsextends beyond studs 24 and 26 to cover them while the inner panels 20aabut the inner surface of the previously formed partition. Suitable trimstrips and 27 may be used to dress off the edges of the partition. Alsoa comer trim strip 29 may be employed at the junctures of the twopartitions.

If it is desired to have'elements 20 and 120 horizontal in bothpartitions as illustrated in FIG. 3, this is readily done as by buildingup one partition first, specifically that on the right side of FIG. 3and then building up the other partition after adding the appropriatecomer studs. In this case also, the

skeletal framework extends in three dimensions from the corner junction.In addition to the struts represented by the toe plates, cap plates, andcorner studs, these partitions may be further reinforced by insertingadditional two by fours" or other equivalent struts through a series ofthe elements 20 between their metal plates 21.

If the structure of the novel type is usedto form the floor partition,not only can supportsextend inside elements 20, but joists (FIG. 10) canextend beneath them for additional support if desired. This type ofconstruction can also be used for the roof-ceiling partition (FIG. 8) aswell as internal-extemal walls 52. Elongated pitch blocks 54 (FIG. 9)interjoin the angular roof partition with the vertical wall partition byhaving an appropriately slanted upper surface and interfitting with thewall partitions as by the tongue and groove connections. This wouldcooperate with, for example, a center beam 56 and supplemental beams 58if necessary.

If desired, the same partition such as the wall illustrated in FIG. 7may include some elements oriented on a vertical basis and otheradjacent elements on the horizontal basis. Further, window and doorframes can be readily interfitted directly with it such as isillustrated by the window in FIG. 7. This window assembly 60 includes aperipheral frame 62 that has a generally U-shaped receiving recess onits outer periphery to receive and interfit with elements 20 as thelatter are assembled. Such a construction enables rapid interlockingassembly of all of the structural components.

The hollow nature of elements 20 enables the electrical wiring,plumbing, insulation, heating ducts, cooling ducts, and the like to bereadily installed into the structures while being enclosed. Thepotential variations of the structure using the regular elements, theedge elements and the interlocked that when assembled, no further finishcoatings such as paper,

vin I, paint or the like are necessary.

he elements 20 also enable coating of the inner face of one or both theinner and outer panels 200 and 20b with a shiny radiant heat reflectorcoating (FIG. 4) prior to assembly into the partitions. This can besupplemented by loose thermal insulation filling to minimize heatconductance.

' Further, it has been found that the strength of the elements I can begreatly increased, as for usage in a floor, by inserting an elongatedtransverse cross piece 80 that extends between the panels 200 and 20b,retained in place by pairs of partial plates 121 as in;FIG. 11.Additional variations may be apparent to those in the trade.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows.

1. A partition of a building structure comprising: a skeletal frameworkand a plurality of elongated interfitted structural elements, each suchelement being formed of a pair of spaced, parallel panels having aheight, a length, and a predetermined spacing therebetween, and beinginterconnected by spaced metal plates therebetween transverse to saidpanels, and having flanges transverse to said plates embedded in saidpanels; said plurality of elements including special edge elements; saidskeletal framework including spaced parallel struts having a widthgreater than their thickness, said panels of said edge elements beingspaced sufficiently to receive said strut width therebetween; said edgeelements having plates of a plate length less than the height of saidpanels by an amount at least the thickness of said struts to enable saidedge elements to each receive a strut therein; and said edge elementsbeing anchored to said struts.

2. The partition in claim 1 wherein said skeletal framework includessecond struts normal to said struts received by said edge elements; andsaid structural elements collectively receiving said second strutsbetween the panels thereof and being secured thereto.

3. The partition in claim 1 wherein said panels of said elements havefinished exterior surfaces.

4. A pair of integral load-bearing partitions of a building structurecomprising: skeletal framework and a plurality of elongated interfittedstructural elements interlocked therewith; said framework includingfirst, second, and third strut means extending from a common corner inthree dimensions normal to each other; said structural elements being intwo groups, each group forming one of the structural loadbearingpartitions; each of said groups being anchored to two of said strutmeans and one of said strut means being common to both groups; saidstructural elements each being formed of a pair of spaced parallelpanels interconnected by spaced rigid metal plates therebetweentransverse to said panels and having flanges transverse to said platesand embedded in said panels; the edgemost ones of said structuralelements in each group having plates of a length substantially less thanthe width of said panels to receive and envelope said strut meansbetween said panels; and elements in both of said groups enveloping saidone strut means.

1. A partition of a building structure comprising: a skeletal frameworkand a plurality of elongated interfitted structural elements, each suchelement being formed of a pair of spaced, parallel panels having aheight, a length, and a predetermined spacing therebetween, and beinginterconnected by spaced metal plates therebetween transverse to saidpanels, and having flanges transverse to said plates embedded in saidpanels; said plurality of elements including special edge elements; saidskeletal framework including spaced parallel struts having a widthgreater than their thickness, said panels of said edge elements beingspaced sufficiently to receive said strut width therebetween; said edgeelements having plates of a plate length less than the height of saidpanels by an amount at least the thickness of said struts to enable saidedge elements to each receive a strut therein; and said edge elementsbeing anchored to said struts.
 2. The partition in claim 1 wherein saidskeletal framework includes second struts normal to said struts receivedby said edge elements; and said structural elements collectivelyreceiving said second struts between the panels thereof and beingsecured thereto.
 3. The partition in claim 1 wherein said panels of saidelements have finished exterior surfaces.
 4. A pair of integralload-bearing partitions of a building structure comprising: skeletalframework and a plurality of elongated interfitted structural elementsinterlocked therewith; said framework including first, second, and thirdstrut means extending from a common corner in three dimensions normal toeach other; said structural elements being in two groups, each groupforming one of the structural load-bearing partitions; each of saidgroups being anchored to two of said strut means and one of said strutmeans being common to both groups; said structural elements each beingformed of a pair of spaced parallel panels interconnected by spacedrigid metal plates therebetween transverse to said panels and havingflanges transverse to said plates and embedded in said panels; theedgemost ones of said structural elements in each group having plates ofa length substantially less than the width of said panels to receive andenvelope said strut means between said panels; and elements in both ofsaid groups enveloping said one strut means.